Computer-implemented systems and methods for optimization of a product inventory by intelligent distribution of inbound products using product assignment validation

ABSTRACT

Computer-implemented systems and methods for intelligent distribution of products are disclosed. The systems and methods may be configured to: receive a request to assign a product to a location; retrieve a plurality of attributes associated with the product from a system configured to store attributes of products; retrieve a plurality of rules from a rules system configured to store rules implemented for assigning a product to a location, the retrieved plurality of rules configured by a user using a user interface; determining the location to store the product by applying the retrieved plurality of attributes to the retrieved plurality of rules; and assigning the product to the determined location.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 16/931,748 (now allowed) filed on Jul. 17, 2020, which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure generally relates to computerized methods and systems for optimizing product inventory by intelligently distributing incoming products. In particular, embodiments of the present disclosure relate to inventive and unconventional systems that assign order quantities of products to fulfillment centers by prioritizing the products based on real-world constraints.

BACKGROUND

Fulfillment centers (FCs) encounter more than millions of products daily as they operate to fulfill consumer orders as soon as the orders are placed and enable shipping carriers to pick up shipments. Operations for managing inventory inside FCs may include receiving merchandise from sellers, stowing the received merchandise for easy picking access, packing the items, verifying the order, and package delivery. Although currently existing FCs and systems for inventory management in FCs are configured to handle large volumes of incoming and outgoing merchandise, a common issue arises when a FC receives more orders than can be handled because the orders are not distributed adequately among multiple FCs. For example, a merchant associated with FCs may order large volumes of products from suppliers for a peak season, but the FCs do not have sufficient resources to receive the ordered products in timely manner. This leads to massive backlog problems at the FCs by slowing down every receiving process that will eventually accumulate the problems. The backlog problems may result a loss in sales because it hampers the merchant from circulating products to make profits.

To mitigate such problems, conventional inventory management systems invest in logistics by hiring more workers in an FC. The benefit of hiring more workers is that additional workers will help with backlogs. Depending on the workers' capabilities, it may be possible to deploy workers in several different roles. While these computerized systems attempt to solve backlog problems in an efficient manner, many times the cost of hiring more workers does not optimize productivity.

Therefore, there is a need for improved methods and systems for keeping product inventory at an optimum level by intelligently assigning proper quantity of inbound products to a plurality of FCs.

SUMMARY

One aspect of the present disclosure is directed to a computer-implemented system for intelligent distribution of products. The system may comprise a memory storing instructions and at least one processor configured to execute the instructions. The instructions may comprise receiving a request to assign a product to a location; retrieving a plurality of attributes associated with the product from a system configured to store attributes of products; retrieving a plurality of rules from a rules system configured to store rules implemented for assigning a product to a location, the retrieved plurality of rules configured by a user using a user interface; determining the location to store the product by applying the retrieved plurality of attributes to the retrieved plurality of rules; and assigning the product to the determined location.

Yet another aspect of the present disclosure is directed to a computer-implemented method for intelligent distribution of products. The method may comprise receiving a request to assign a product to a location; retrieving a plurality of attributes associated with the product from a system configured to store attributes of products; retrieving a plurality of rules from a rules system configured to store rules implemented for assigning a product to a location, the retrieved plurality of rules configured by a user using a user interface; determining the location to store the product by applying the retrieved plurality of attributes to the retrieved plurality of rules; and assigning the product to the determined location.

Still further, another aspect of the present disclosure is directed to a computer-implemented system for intelligent distribution of products. The system may comprise receiving a request to assign a product to a location; retrieving a plurality of attributes associated with the product from a system configured to store attributes of products; retrieving a plurality of rules from a rules system configured to store rules implemented for assigning a product to a location, the retrieved plurality of rules configured by a user using a user interface; determining the location to store the product by applying the retrieved plurality of attributes to the retrieved plurality of rules; assigning the product to the determined location; operating a validation on the assigned product; reassigning the product to another location based on the validation; and adjusting the priority associated with each of the plurality of rules based on the validation.

Other systems, methods, and computer-readable media are also discussed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic block diagram illustrating an exemplary embodiment of a network comprising computerized systems for communications enabling shipping, transportation, and logistics operations, consistent with the disclosed embodiments.

FIG. 1B depicts a sample Search Result Page (SRP) that includes one or more search results satisfying a search request along with interactive user interface elements, consistent with the disclosed embodiments.

FIG. 1C depicts a sample Single Display Page (SDP) that includes a product and information about the product along with interactive user interface elements, consistent with the disclosed embodiments.

FIG. 1D depicts a sample Cart page that includes items in a virtual shopping cart along with interactive user interface elements, consistent with the disclosed embodiments.

FIG. 1E depicts a sample Order page that includes items from the virtual shopping cart along with information regarding purchase and shipping, along with interactive user interface elements, consistent with the disclosed embodiments.

FIG. 2 is a diagrammatic illustration of an exemplary fulfillment center (FC) configured to utilize disclosed computerized systems, consistent with the disclosed embodiments.

FIG. 3 is a schematic block diagram illustrating an exemplary embodiment of a networked environment comprising computerized systems for keeping product inventory at an optimum level, consistent with the disclosed embodiments.

FIG. 4 is a block diagram including components that may determine a FC in which to store a product and assign the product to the determined FC, consistent with disclosed embodiments.

FIG. 5 is an exemplary flow chart of a process for intelligent distribution of products, consistent with the disclosed embodiments.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar parts. While several illustrative embodiments are described herein, modifications, adaptations and other implementations are possible. For example, substitutions, additions, or modifications may be made to the components and steps illustrated in the drawings, and the illustrative methods described herein may be modified by substituting, reordering, removing, or adding steps to the disclosed methods. Accordingly, the following detailed description is not limited to the disclosed embodiments and examples. Instead, the proper scope of the invention is defined by the appended claims.

Embodiments of the present disclosure are directed to computer-implemented systems and methods for optimizing product inventory by assigning proper quantities of products to fulfillment centers. The disclosed embodiments provide innovative technical features that allow for automated product assignment based on real-world constraints at a national level. For example, the disclosed embodiments enable efficient assignment of an order quantity for a product to fulfillment centers by utilizing a set of rules or a logistical regression model on real-world constraints at a national level.

For example, a first system may receive a request to assign a product to a location from a user device. The first system may retrieve a plurality of attributes associated with the product from a second system that is configured to store attributes of products, retrieve the requested plurality of attributes from a FO system, and transmit the retrieved plurality of attributes to the first system. The plurality of attributes may include stock keeping unit (SKU) dimensions (length, width, height, and weight), a unit quantity, a storage type, a category, a price, a sales band, a velocity, a delivery type, a supplier, or the like. The first system may retrieve a plurality of rules from a rules system that is configured to store a plurality of rules, retrieve the requested plurality of rules, and transmit the retrieved plurality of rules to first system. The retrieved plurality of rules can be applied sequentially based on a priority associated with each rule.

In some embodiments, the mapping system may determine a FC in which to store the product by applying the retrieved plurality of attributes to the retrieved plurality of rules. For example, the mapping system may apply the plurality of attributes to the plurality of rules in order of its priority. When the mapping system determines the FC, the mapping system may assign the product to the determined FC. The mapping system may operate a validation on the assigned product and retrieve one or more validation use cases from a storage system. The validation use cases may include analyzing the assigned product to determine whether the assignment is empty, the vendor is empty or null, the assignment includes an empty FC list, an invalid FC list, or duplicate records.

Referring to FIG. 1A, a schematic block diagram 100 illustrating an exemplary embodiment of a system comprising computerized systems for communications enabling shipping, transportation, and logistics operations is shown. As illustrated in FIG. 1A, system 100 may include a variety of systems, each of which may be connected to one another via one or more networks. The systems may also be connected to one another via a direct connection, for example, using a cable. The depicted systems include a shipment authority technology (SAT) system 101, an external front end system 103, an internal front end system 105, a transportation system 107, mobile devices 107A, 107B, and 107C, seller portal 109, shipment and order tracking (SOT) system 111, fulfillment optimization (FO) system 113, fulfillment messaging gateway (FMG) 115, supply chain management (SCM) system 117, warehouse management system 119, mobile devices 119A, 119B, and 119C (depicted as being inside of fulfillment center (FC) 200), 3^(rd) party fulfillment systems 121A, 121B, and 121C, fulfillment center authorization system (FC Auth) 123, and labor management system (LMS) 125.

SAT system 101, in some embodiments, may be implemented as a computer system that monitors order status and delivery status. For example, SAT system 101 may determine whether an order is past its Promised Delivery Date (PDD) and may take appropriate action, including initiating a new order, reshipping the items in the non-delivered order, canceling the non-delivered order, initiating contact with the ordering customer, or the like. SAT system 101 may also monitor other data, including output (such as a number of packages shipped during a particular time period) and input (such as the number of empty cardboard boxes received for use in shipping). SAT system 101 may also act as a gateway between different devices in system 100, enabling communication (e.g., using store-and-forward or other techniques) between devices such as external front end system 103 and FO system 113.

External front end system 103, in some embodiments, may be implemented as a computer system that enables external users to interact with one or more systems in system 100. For example, in embodiments where system 100 enables the presentation of systems to enable users to place an order for an item, external front end system 103 may be implemented as a web server that receives search requests, presents item pages, and solicits payment information. For example, external front end system 103 may be implemented as a computer or computers running software such as the Apache HTTP Server, Microsoft Internet Information Services (IIS), NGINX, or the like. In other embodiments, external front end system 103 may run custom web server software designed to receive and process requests from external devices (e.g., mobile device 102A or computer 102B), acquire information from databases and other data stores based on those requests, and provide responses to the received requests based on acquired information.

In some embodiments, external front end system 103 may include one or more of a web caching system, a database, a search system, or a payment system. In one aspect, external front end system 103 may comprise one or more of these systems, while in another aspect, external front end system 103 may comprise interfaces (e.g., server-to-server, database-to-database, or other network connections) connected to one or more of these systems.

An illustrative set of steps, illustrated by FIGS. 1B, 1C, 1D, and 1E, will help to describe some operations of external front end system 103. External front end system 103 may receive information from systems or devices in system 100 for presentation and/or display. For example, external front end system 103 may host or provide one or more web pages, including a Search Result Page (SRP) (e.g., FIG. 1B), a Single Detail Page (SDP) (e.g., FIG. 1C), a Cart page (e.g., FIG. 1D), or an Order page (e.g., FIG. 1E). A user device (e.g., using mobile device 102A or computer 102B) may navigate to external front end system 103 and request a search by entering information into a search box. External front end system 103 may request information from one or more systems in system 100. For example, external front end system 103 may request information from FO System 113 that satisfies the search request. External front end system 103 may also request and receive (from FO System 113) a Promised Delivery Date or “PDD” for each product included in the search results. The PDD, in some embodiments, may represent an estimate of when a package containing the product will arrive at the user's desired location or a date by which the product is promised to be delivered at the user's desired location if ordered within a particular period of time, for example, by the end of the day (11:59 PM). (PDD is discussed further below with respect to FO System 113.)

External front end system 103 may prepare an SRP (e.g., FIG. 1B) based on the information. The SRP may include information that satisfies the search request. For example, this may include pictures of products that satisfy the search request. The SRP may also include respective prices for each product, or information relating to enhanced delivery options for each product, PDD, weight, size, offers, discounts, or the like. External front end system 103 may send the SRP to the requesting user device (e.g., via a network).

A user device may then select a product from the SRP, e.g., by clicking or tapping a user interface, or using another input device, to select a product represented on the SRP. The user device may formulate a request for information on the selected product and send it to external front end system 103. In response, external front end system 103 may request information related to the selected product. For example, the information may include additional information beyond that presented for a product on the respective SRP. This could include, for example, shelf life, country of origin, weight, size, number of items in package, handling instructions, or other information about the product. The information could also include recommendations for similar products (based on, for example, big data and/or machine learning analysis of customers who bought this product and at least one other product), answers to frequently asked questions, reviews from customers, manufacturer information, pictures, or the like.

External front end system 103 may prepare an SDP (Single Detail Page) (e.g., FIG. 1C) based on the received product information. The SDP may also include other interactive elements such as a “Buy Now” button, a “Add to Cart” button, a quantity field, a picture of the item, or the like. The SDP may further include a list of sellers that offer the product. The list may be ordered based on the price each seller offers such that the seller that offers to sell the product at the lowest price may be listed at the top. The list may also be ordered based on the seller ranking such that the highest ranked seller may be listed at the top. The seller ranking may be formulated based on multiple factors, including, for example, the seller's past track record of meeting a promised PDD. External front end system 103 may deliver the SDP to the requesting user device (e.g., via a network).

The requesting user device may receive the SDP which lists the product information. Upon receiving the SDP, the user device may then interact with the SDP. For example, a user of the requesting user device may click or otherwise interact with a “Place in Cart” button on the SDP. This adds the product to a shopping cart associated with the user. The user device may transmit this request to add the product to the shopping cart to external front end system 103.

External front end system 103 may generate a Cart page (e.g., FIG. 1D). The Cart page, in some embodiments, lists the products that the user has added to a virtual “shopping cart.” A user device may request the Cart page by clicking on or otherwise interacting with an icon on the SRP, SDP, or other pages. The Cart page may, in some embodiments, list all products that the user has added to the shopping cart, as well as information about the products in the cart such as a quantity of each product, a price for each product per item, a price for each product based on an associated quantity, information regarding PDD, a delivery method, a shipping cost, user interface elements for modifying the products in the shopping cart (e.g., deletion or modification of a quantity), options for ordering other product or setting up periodic delivery of products, options for setting up interest payments, user interface elements for proceeding to purchase, or the like. A user at a user device may click on or otherwise interact with a user interface element (e.g., a button that reads “Buy Now”) to initiate the purchase of the product in the shopping cart. Upon doing so, the user device may transmit this request to initiate the purchase to external front end system 103.

External front end system 103 may generate an Order page (e.g., FIG. 1E) in response to receiving the request to initiate a purchase. The Order page, in some embodiments, re-lists the items from the shopping cart and requests input of payment and shipping information. For example, the Order page may include a section requesting information about the purchaser of the items in the shopping cart (e.g., name, address, e-mail address, phone number), information about the recipient (e.g., name, address, phone number, delivery information), shipping information (e.g., speed/method of delivery and/or pickup), payment information (e.g., credit card, bank transfer, check, stored credit), user interface elements to request a cash receipt (e.g., for tax purposes), or the like. External front end system 103 may send the Order page to the user device.

The user device may enter information on the Order page and click or otherwise interact with a user interface element that sends the information to external front end system 103. From there, external front end system 103 may send the information to different systems in system 100 to enable the creation and processing of a new order with the products in the shopping cart.

In some embodiments, external front end system 103 may be further configured to enable sellers to transmit and receive information relating to orders.

Internal front end system 105, in some embodiments, may be implemented as a computer system that enables internal users (e.g., employees of an organization that owns, operates, or leases system 100) to interact with one or more systems in system 100. For example, in embodiments where network 101 enables the presentation of systems to enable users to place an order for an item, internal front end system 105 may be implemented as a web server that enables internal users to view diagnostic and statistical information about orders, modify item information, or review statistics relating to orders. For example, internal front end system 105 may be implemented as a computer or computers running software such as the Apache HTTP Server, Microsoft Internet Information Services (IIS), NGINX, or the like. In other embodiments, internal front end system 105 may run custom web server software designed to receive and process requests from systems or devices depicted in system 100 (as well as other devices not depicted), acquire information from databases and other data stores based on those requests, and provide responses to the received requests based on acquired information.

In some embodiments, internal front end system 105 may include one or more of a web caching system, a database, a search system, a payment system, an analytics system, an order monitoring system, or the like. In one aspect, internal front end system 105 may comprise one or more of these systems, while in another aspect, internal front end system 105 may comprise interfaces (e.g., server-to-server, database-to-database, or other network connections) connected to one or more of these systems.

Transportation system 107, in some embodiments, may be implemented as a computer system that enables communication between systems or devices in system 100 and mobile devices 107A-107C. Transportation system 107, in some embodiments, may receive information from one or more mobile devices 107A-107C (e.g., mobile phones, smart phones, PDAs, or the like). For example, in some embodiments, mobile devices 107A-107C may comprise devices operated by delivery workers. The delivery workers, who may be permanent, temporary, or shift employees, may utilize mobile devices 107A-107C to effect delivery of packages containing the products ordered by users. For example, to deliver a package, the delivery worker may receive a notification on a mobile device indicating which package to deliver and where to deliver it. Upon arriving at the delivery location, the delivery worker may locate the package (e.g., in the back of a truck or in a crate of packages), scan or otherwise capture data associated with an identifier on the package (e.g., a barcode, an image, a text string, an RFID tag, or the like) using the mobile device, and deliver the package (e.g., by leaving it at a front door, leaving it with a security guard, handing it to the recipient, or the like). In some embodiments, the delivery worker may capture photo(s) of the package and/or may obtain a signature using the mobile device. The mobile device may send information to transportation system 107 including information about the delivery, including, for example, time, date, GPS location, photo(s), an identifier associated with the delivery worker, an identifier associated with the mobile device, or the like. Transportation system 107 may store this information in a database (not pictured) for access by other systems in system 100. Transportation system 107 may, in some embodiments, use this information to prepare and send tracking data to other systems indicating the location of a particular package.

In some embodiments, certain users may use one kind of mobile device (e.g., permanent workers may use a specialized PDA with custom hardware such as a barcode scanner, stylus, and other devices) while other users may use other kinds of mobile devices (e.g., temporary or shift workers may utilize off-the-shelf mobile phones and/or smartphones).

In some embodiments, transportation system 107 may associate a user with each device. For example, transportation system 107 may store an association between a user (represented by, e.g., a user identifier, an employee identifier, or a phone number) and a mobile device (represented by, e.g., an International Mobile Equipment Identity (IMEI), an International Mobile Subscription Identifier (IMSI), a phone number, a Universal Unique Identifier (UUID), or a Globally Unique Identifier (GUID)). Transportation system 107 may use this association in conjunction with data received on deliveries to analyze data stored in the database in order to determine, among other things, a location of the worker, an efficiency of the worker, or a speed of the worker.

Seller portal 109, in some embodiments, may be implemented as a computer system that enables sellers or other external entities to electronically communicate with one or more systems in system 100. For example, a seller may utilize a computer system (not pictured) to upload or provide product information, order information, contact information, or the like, for products that the seller wishes to sell through system 100 using seller portal 109.

Shipment and order tracking system 111, in some embodiments, may be implemented as a computer system that receives, stores, and forwards information regarding the location of packages containing products ordered by customers (e.g., by a user using devices 102A-102B). In some embodiments, shipment and order tracking system 111 may request or store information from web servers (not pictured) operated by shipping companies that deliver packages containing products ordered by customers.

In some embodiments, shipment and order tracking system 111 may request and store information from systems depicted in system 100. For example, shipment and order tracking system 111 may request information from transportation system 107. As discussed above, transportation system 107 may receive information from one or more mobile devices 107A-107C (e.g., mobile phones, smart phones, PDAs, or the like) that are associated with one or more of a user (e.g., a delivery worker) or a vehicle (e.g., a delivery truck). In some embodiments, shipment and order tracking system 111 may also request information from warehouse management system (WMS) 119 to determine the location of individual products inside of a fulfillment center (e.g., fulfillment center 200). Shipment and order tracking system 111 may request data from one or more of transportation system 107 or WMS 119, process it, and present it to a device (e.g., user devices 102A and 102B) upon request.

Fulfillment optimization (FO) system 113, in some embodiments, may be implemented as a computer system that stores information for customer orders from other systems (e.g., external front end system 103 and/or shipment and order tracking system 111). FO system 113 may also store information describing where particular items are held or stored. For example, certain items may be stored only in one fulfillment center, while certain other items may be stored in multiple fulfillment centers. In still other embodiments, certain fulfilment centers may be designed to store only a particular set of items (e.g., fresh produce or frozen products). FO system 113 stores this information as well as associated information (e.g., quantity, size, date of receipt, expiration date, etc.).

FO system 113 may also calculate a corresponding PDD (promised delivery date) for each product. The PDD, in some embodiments, may be based on one or more factors. For example, FO system 113 may calculate a PDD for a product based on a past demand for a product (e.g., how many times that product was ordered during a period of time), an expected demand for a product (e.g., how many customers are forecast to order the product during an upcoming period of time), a network-wide past demand indicating how many products were ordered during a period of time, a network-wide expected demand indicating how many products are expected to be ordered during an upcoming period of time, one or more counts of the product stored in each fulfillment center 200, which fulfillment center stores each product, expected or current orders for that product, or the like.

In some embodiments, FO system 113 may determine a PDD for each product on a periodic basis (e.g., hourly) and store it in a database for retrieval or sending to other systems (e.g., external front end system 103, SAT system 101, shipment and order tracking system 111). In other embodiments, FO system 113 may receive electronic requests from one or more systems (e.g., external front end system 103, SAT system 101, shipment and order tracking system 111) and calculate the PDD on demand.

Fulfilment messaging gateway (FMG) 115, in some embodiments, may be implemented as a computer system that receives a request or response in one format or protocol from one or more systems in system 100, such as FO system 113, converts it to another format or protocol, and forward it in the converted format or protocol to other systems, such as WMS 119 or 3^(rd) party fulfillment systems 121A, 121B, or 121C, and vice versa.

Supply chain management (SCM) system 117, in some embodiments, may be implemented as a computer system that performs forecasting functions. For example, SCM system 117 may forecast a level of demand for a particular product based on, for example, based on a past demand for products, an expected demand for a product, a network-wide past demand, a network-wide expected demand, a count products stored in each fulfillment center 200, expected or current orders for each product, or the like. In response to this forecasted level and the amount of each product across all fulfillment centers, SCM system 117 may generate one or more purchase orders to purchase and stock a sufficient quantity to satisfy the forecasted demand for a particular product.

Warehouse management system (WMS) 119, in some embodiments, may be implemented as a computer system that monitors workflow. For example, WMS 119 may receive event data from individual devices (e.g., devices 107A-107C or 119A-119C) indicating discrete events. For example, WMS 119 may receive event data indicating the use of one of these devices to scan a package. As discussed below with respect to fulfillment center 200 and FIG. 2 , during the fulfillment process, a package identifier (e.g., a barcode or RFID tag data) may be scanned or read by machines at particular stages (e.g., automated or handheld barcode scanners, RFID readers, high-speed cameras, devices such as tablet 119A, mobile device/PDA 1198, computer 119C, or the like). WMS 119 may store each event indicating a scan or a read of a package identifier in a corresponding database (not pictured) along with the package identifier, a time, date, location, user identifier, or other information, and may provide this information to other systems (e.g., shipment and order tracking system 111).

WMS 119, in some embodiments, may store information associating one or more devices (e.g., devices 107A-107C or 119A-119C) with one or more users associated with system 100. For example, in some situations, a user (such as a part- or full-time employee) may be associated with a mobile device in that the user owns the mobile device (e.g., the mobile device is a smartphone). In other situations, a user may be associated with a mobile device in that the user is temporarily in custody of the mobile device (e.g., the user checked the mobile device out at the start of the day, will use it during the day, and will return it at the end of the day).

WMS 119, in some embodiments, may maintain a work log for each user associated with system 100. For example, WMS 119 may store information associated with each employee, including any assigned processes (e.g., unloading trucks, picking items from a pick zone, rebin wall work, packing items), a user identifier, a location (e.g., a floor or zone in a fulfillment center 200), a number of units moved through the system by the employee (e.g., number of items picked, number of items packed), an identifier associated with a device (e.g., devices 119A-119C), or the like. In some embodiments, WMS 119 may receive check-in and check-out information from a timekeeping system, such as a timekeeping system operated on a device 119A-119C.

3^(rd) party fulfillment (3PL) systems 121A-121C, in some embodiments, represent computer systems associated with third-party providers of logistics and products. For example, while some products are stored in fulfillment center 200 (as discussed below with respect to FIG. 2 ), other products may be stored off-site, may be produced on demand, or may be otherwise unavailable for storage in fulfillment center 200. 3PL systems 121A-121C may be configured to receive orders from FO system 113 (e.g., through FMG 115) and may provide products and/or services (e.g., delivery or installation) to customers directly. In some embodiments, one or more of 3PL systems 121A-121C may be part of system 100, while in other embodiments, one or more of 3PL systems 121A-121C may be outside of system 100 (e.g., owned or operated by a third-party provider).

Fulfillment Center Auth system (FC Auth) 123, in some embodiments, may be implemented as a computer system with a variety of functions. For example, in some embodiments, FC Auth 123 may act as a single-sign on (SSO) service for one or more other systems in system 100. For example, FC Auth 123 may enable a user to log in via internal front end system 105, determine that the user has similar privileges to access resources at shipment and order tracking system 111, and enable the user to access those privileges without requiring a second log in process. FC Auth 123, in other embodiments, may enable users (e.g., employees) to associate themselves with a particular task. For example, some employees may not have an electronic device (such as devices 119A-119C) and may instead move from task to task, and zone to zone, within a fulfillment center 200, during the course of a day. FC Auth 123 may be configured to enable those employees to indicate what task they are performing and what zone they are in at different times of day.

Labor management system (LMS) 125, in some embodiments, may be implemented as a computer system that stores attendance and overtime information for employees (including full-time and part-time employees). For example, LMS 125 may receive information from FC Auth 123, WMA 119, devices 119A-119C, transportation system 107, and/or devices 107A-107C.

The particular configuration depicted in FIG. 1A is an example only. For example, while FIG. 1A depicts FC Auth system 123 connected to FO system 113, not all embodiments require this particular configuration. Indeed, in some embodiments, the systems in system 100 may be connected to one another through one or more public or private networks, including the Internet, an Intranet, a WAN (Wide-Area Network), a MAN (Metropolitan-Area Network), a wireless network compliant with the IEEE 802.11a/b/g/n Standards, a leased line, or the like. In some embodiments, one or more of the systems in system 100 may be implemented as one or more virtual servers implemented at a data center, server farm, or the like.

FIG. 2 depicts a fulfillment center 200. Fulfillment center 200 is an example of a physical location that stores items for shipping to customers when ordered. Fulfillment center (FC) 200 may be divided into multiple zones, each of which are depicted in FIG. 2 . These “zones,” in some embodiments, may be thought of as virtual divisions between different stages of a process of receiving items, storing the items, retrieving the items, and shipping the items. So while the “zones” are depicted in FIG. 2 , other divisions of zones are possible, and the zones in FIG. 2 may be omitted, duplicated, or modified in some embodiments.

Inbound zone 203 represents an area of FC 200 where items are received from sellers who wish to sell products using system 100 from FIG. 1A. For example, a seller may deliver items 202A and 202B using truck 201. Item 202A may represent a single item large enough to occupy its own shipping pallet, while item 202B may represent a set of items that are stacked together on the same pallet to save space.

A worker will receive the items in inbound zone 203 and may optionally check the items for damage and correctness using a computer system (not pictured). For example, the worker may use a computer system to compare the quantity of items 202A and 202B to an ordered quantity of items. If the quantity does not match, that worker may refuse one or more of items 202A or 202B. If the quantity does match, the worker may move those items (using, e.g., a dolly, a handtruck, a forklift, or manually) to buffer zone 205. Buffer zone 205 may be a temporary storage area for items that are not currently needed in the picking zone, for example, because there is a high enough quantity of that item in the picking zone to satisfy forecasted demand. In some embodiments, forklifts 206 operate to move items around buffer zone 205 and between inbound zone 203 and drop zone 207. If there is a need for items 202A or 202B in the picking zone (e.g., because of forecasted demand), a forklift may move items 202A or 202B to drop zone 207.

Drop zone 207 may be an area of FC 200 that stores items before they are moved to picking zone 209. A worker assigned to the picking task (a “picker”) may approach items 202A and 202B in the picking zone, scan a barcode for the picking zone, and scan barcodes associated with items 202A and 202B using a mobile device (e.g., device 119B). The picker may then take the item to picking zone 209 (e.g., by placing it on a cart or carrying it).

Picking zone 209 may be an area of FC 200 where items 208 are stored on storage units 210. In some embodiments, storage units 210 may comprise one or more of physical shelving, bookshelves, boxes, totes, refrigerators, freezers, cold stores, or the like. In some embodiments, picking zone 209 may be organized into multiple floors. In some embodiments, workers or machines may move items into picking zone 209 in multiple ways, including, for example, a forklift, an elevator, a conveyor belt, a cart, a handtruck, a dolly, an automated robot or device, or manually. For example, a picker may place items 202A and 202B on a handtruck or cart in drop zone 207 and walk items 202A and 202B to picking zone 209.

A picker may receive an instruction to place (or “stow”) the items in particular spots in picking zone 209, such as a particular space on a storage unit 210. For example, a picker may scan item 202A using a mobile device (e.g., device 119B). The device may indicate where the picker should stow item 202A, for example, using a system that indicate an aisle, shelf, and location. The device may then prompt the picker to scan a barcode at that location before stowing item 202A in that location. The device may send (e.g., via a wireless network) data to a computer system such as WMS 119 in FIG. 1A indicating that item 202A has been stowed at the location by the user using device 1198.

Once a user places an order, a picker may receive an instruction on device 1198 to retrieve one or more items 208 from storage unit 210. The picker may retrieve item 208, scan a barcode on item 208, and place it on transport mechanism 214. While transport mechanism 214 is represented as a slide, in some embodiments, transport mechanism may be implemented as one or more of a conveyor belt, an elevator, a cart, a forklift, a handtruck, a dolly, a cart, or the like. Item 208 may then arrive at packing zone 211.

Packing zone 211 may be an area of FC 200 where items are received from picking zone 209 and packed into boxes or bags for eventual shipping to customers. In packing zone 211, a worker assigned to receiving items (a “rebin worker”) will receive item 208 from picking zone 209 and determine what order it corresponds to. For example, the rebin worker may use a device, such as computer 119C, to scan a barcode on item 208. Computer 119C may indicate visually which order item 208 is associated with. This may include, for example, a space or “cell” on a wall 216 that corresponds to an order. Once the order is complete (e.g., because the cell contains all items for the order), the rebin worker may indicate to a packing worker (or “packer”) that the order is complete. The packer may retrieve the items from the cell and place them in a box or bag for shipping. The packer may then send the box or bag to a hub zone 213, e.g., via forklift, cart, dolly, handtruck, conveyor belt, manually, or otherwise.

Hub zone 213 may be an area of FC 200 that receives all boxes or bags (“packages”) from packing zone 211. Workers and/or machines in hub zone 213 may retrieve package 218 and determine which portion of a delivery area each package is intended to go to, and route the package to an appropriate camp zone 215. For example, if the delivery area has two smaller sub-areas, packages will go to one of two camp zones 215. In some embodiments, a worker or machine may scan a package (e.g., using one of devices 119A-119C) to determine its eventual destination. Routing the package to camp zone 215 may comprise, for example, determining a portion of a geographical area that the package is destined for (e.g., based on a postal code) and determining a camp zone 215 associated with the portion of the geographical area.

Camp zone 215, in some embodiments, may comprise one or more buildings, one or more physical spaces, or one or more areas, where packages are received from hub zone 213 for sorting into routes and/or sub-routes. In some embodiments, camp zone 215 is physically separate from FC 200 while in other embodiments camp zone 215 may form a part of FC 200.

Workers and/or machines in camp zone 215 may determine which route and/or sub-route a package 220 should be associated with, for example, based on a comparison of the destination to an existing route and/or sub-route, a calculation of workload for each route and/or sub-route, the time of day, a shipping method, the cost to ship the package 220, a PDD associated with the items in package 220, or the like. In some embodiments, a worker or machine may scan a package (e.g., using one of devices 119A-119C) to determine its eventual destination. Once package 220 is assigned to a particular route and/or sub-route, a worker and/or machine may move package 220 to be shipped. In exemplary FIG. 2 , camp zone 215 includes a truck 222, a car 226, and delivery workers 224A and 224B. In some embodiments, truck 222 may be driven by delivery worker 224A, where delivery worker 224A is a full-time employee that delivers packages for FC 200 and truck 222 is owned, leased, or operated by the same company that owns, leases, or operates FC 200. In some embodiments, car 226 may be driven by delivery worker 224B, where delivery worker 224B is a “flex” or occasional worker that is delivering on an as-needed basis (e.g., seasonally). Car 226 may be owned, leased, or operated by delivery worker 224B.

FIG. 3 is a schematic block diagram illustrating an exemplary embodiment of a networked environment 300 comprising computerized systems for keeping product inventory at an optimum level. Environment 300 may include a variety of systems, each of which may be connected to one another via one or more networks. The systems may also be connected to one another via a direct connection, for example, using a cable. The depicted systems include a FO system 311, a FC database 312, an external front end system 313, a supply chain management system 320, and one or more user terminals 330. FO system 311 and external front end system 313 may be similar in design, function, or operation to FO system 113 and external front end system 103 described above with respect to FIG. 1A.

FC database 312 may be implemented as one or more computer systems that collect, accrue, and/or generate various data accrued from various activities at FC 200 as described above with respect to FIG. 2 . For example, data accrued at FC database 312 may include, among others, product identifiers (e.g., stock keeping unit (SKU)) of every product handled by a particular FC (e.g., FC 200), an inventory level of each product over time, and frequency and occurrences of out of stock events for each product.

In some embodiments, FC database 312 may comprise FC A database 312A, FC B database 312B, and FC C database 312C, which represent databases associated with FCs A-C. While only three FCs and corresponding FC databases 312A-C are depicted in FIG. 3 , the number is only exemplary and there may be more FCs and a corresponding number of FC databases. In other embodiments, FC database 312 may be a centralized database collecting and storing data from all FCs. Regardless of whether FC database 312 includes individual databases (e.g., 312A-C) or one centralized database, the databases may include cloud-based databases or on-premise databases. Also in some embodiments, such databases may comprise one or more hard disk drives, one or more solid state drives, or one or more non-transitory memories.

Supply Chain Management System (SCM) 320 may be similar in design, function, or operation to SCM 117 described above with respect to FIG. 1A. Alternatively or additionally, SCM 320 may be configured to aggregate data from FO system 311, FC database 312, and external front end system 313 in order to forecast a level of demand for a particular product and generate one or more purchase orders in a process consistent with the disclosed embodiments.

In some embodiments, SCM 320 comprises a data science module 321, a demand forecast generator 322, a target inventory plan system (TIP) 323, an inbound prioritization and shuffling system (IPS) 324, a manual order submission platform 325, a purchase order (PO) generator 326, and a report generator 327.

In some embodiments, SCM 320 may comprise one or more processors, one or more memories, and one or more input/output (I/O) devices. SCM 320 may take the form of a server, general-purpose computer, a mainframe computer, a special-purpose computing device such as a graphical processing unit (GPU), laptop, or any combination of these computing devices. In these embodiments, components of SCM 320 (e.g., data science module 321, demand forecast generator 322, TIP 323, IPS 324, manual order submission platform 325, PO generator 326, and report generator 327) may be implemented as one or more functional units performed by one or more processors based on instructions stored in the one or more memories. SCM 320 may be a standalone system, or it may be part of a subsystem, which may be part of a larger system.

Alternatively, components of SCM 320 may be implemented as one or more computer systems communicating with each other via a network. In this embodiment, each of the one or more computer systems may comprise one or more processors, one or more memories (i.e., non-transitory computer-readable media), and one or more input/output (I/O) devices. In some embodiments, each of the one or more computer systems may take the form of a server, general-purpose computer, a mainframe computer, a special-purpose computing device such as a GPU, laptop, or any combination of these computing devices.

Data science module 321, in some embodiments, may include one or more computing devices configured to determine various parameters or models for use by other components of SCM 320. For example, data science module 321 may develop a forecast model used by demand forecast generator 322 that determines a level of demand for each product. In some embodiments, data science module 321 may retrieve order information from FO system 311 and glance view (i.e., number of webpage views for the product) from external front end system 313 to train the forecast model and anticipate a level of future demand. The order information may include sales statistics such as a number of items sold over time, a number of items sold during promotion periods, and a number of items sold during regular periods. Data science module 321 may train the forecast model based on parameters such as the sales statistics, glance view, season, day of the week, upcoming holidays, and the like. In some embodiments, data science module 321 may also receive data from inbound zone 203 of FIG. 2 as products ordered via POs generated by PO generator 326 are received. Data science module 321 may use such data to determine various supplier statistics such as a particular supplier's fulfillment ratio (i.e., a percentage of products that are received in a saleable condition compared to an ordered quantity), an estimated lead time and shipping period, or the like.

Demand forecast generator 322, in some embodiments, may include one or more computing devices configured to forecast a level of demand for a particular product using the forecast model developed by data science module 321. More specifically, the forecast model may output a demand forecast quantity for each product, where the demand forecast quantity is a specific quantity of the product expected to be sold to one or more customers in a given period (e.g., a day). In some embodiments, demand forecast generator 322 may output demand forecast quantities for each given period over a predetermined period (e.g., a demand forecast quantity for each day over a 5-week period). Each demand forecast quantity may also comprise a standard deviation quantity (e.g., ±5) or a range (e.g., maximum of 30 and minimum of 25) to provide more flexibility in optimizing product inventory levels.

TIP 323, in some embodiments, may include one or more computing devices configured to determine a recommended order quantity for each product. TIP 323 may determine the recommended order quantity by first determining preliminary order quantities for the products and constraining the preliminary order quantities with real-world constraints (e.g., using sales statistics, the current product inventory levels, the currently ordered quantities, etc.).

TIP 323 may receive a demand forecast quantity for each product from demand forecast generator 322. In some embodiments, the demand forecast quantities may be in the form of a table of numerical values organized by SKU in a first dimension and number of units forecasted to be sold for a given day in a second dimension. The table may also comprise additional dimensions devoted to other parameters of the demand forecast quantity such as standard deviation, maximum, minimum, average, or the like, of the forecasted quantities of product. Alternatively, the demand forecast quantities may take the form of multiple arrays of values organized by SKU and dedicated to each parameter. Other suitable forms of organizing the same data are equally applicable as known in the art and are within the scope of this invention.

In some embodiments, TIP 323 may receive, from data science module 321, supplier statistics data of one or more suppliers that supply the products. The supplier statistics data may comprise a set of information (e.g., fulfillment ratio described above) associated with each supplier. In some embodiments, there may be multiple sets of supplier statistics data for a particular supplier where each set of data is associated with a particular product supplied by the supplier.

TIP 323 may also receive, in some embodiments, from FC databases 312, current product inventory levels and currently ordered quantities of each product. The current product inventory level may refer to an instantaneous count of a particular product at the time of data retrieval, and the currently ordered quantity may refer to a total quantity of a particular product that has been ordered through one or more POs generated in the past and is waiting for delivery to corresponding FCs.

TIP 323 may determine recommended order quantities for each product by determining preliminary order quantities for each product and reducing the preliminary order quantities based on a range of parameters. In some embodiments, a preliminary order quantity for a particular product may be a function of at least one of its demand forecast quantity, a coverage period, a safety stock period, current inventory level, currently ordered quantity, a fulfillment ratio, and a case quantity. For example, TIP 323 may determine a preliminary order quantity with formula (1):

$\begin{matrix} {Q_{p} = {{{ceiling}\left( \frac{\left( {\sum\limits_{n = 0}^{P_{c} + P_{s} - 1}\; Q_{fn}} \right) - Q_{c} - Q_{o}}{C} \right)} \cdot C}} & (1) \end{matrix}$ where Q_(p) is a preliminary order quantity for a particular product; Q_(fn) is a demand forecast quantity of the product for nth day from the time of calculation; Q_(c) is the current inventory level of the product; Q_(o) is the currently ordered quantity; P_(c) is the coverage period; P_(s) is the safety stock period; and C is the case quantity.

As used herein, a coverage period may refer to a length of time (e.g., number of days) one PO is planned to cover; and a safety stock period may refer to an additional length of time (e.g., additional number of days) the PO may cover in the case of an unexpected event such as a sudden increase in demand or a delayed delivery. For example, given the following table of sample demand forecast quantities for product X, a coverage period for a PO generated at day D may be 5 and a safety stock period may be 1, in which case, Σ_(n=0) ^(P) ^(c) ^(+P) ^(s) ⁻¹Q_(fn) would equal 37+37+35+40+41+34=224.

TABLE 1 Sample demand forecast quantity for product X over 9 days Forecast D D + 1 D + 2 D + 3 D + 4 D + 5 D + 6 D + 7 D + 8 Q_(fn) 37 37 35 40 41 34 37 39 41

From this quantity, 224 units of product X, TIP 323 may subtract the current inventory level (e.g., 60 units) and the currently ordered quantity (e.g., 40), which comes out to be 124 units. This number may be rounded up to a multiple of the case quantity (i.e., the number of units in which the product is packaged, such as the number of units in a box or a pallet) by being divided by the case quantity, being rounded up to an integer, and being multiplied by the case quantity again, which, in this example, may be 130 units given a case quantity of 10 as an example.

In some embodiments, the coverage period may be a predetermined length of time equal to or greater than an expected length of time a corresponding supplier may take to deliver the products from the date of PO generation. Additionally or alternatively, TIP 323 may also adjust the coverage period based on other factors such as the day of the week, anticipated delay, or the like. Furthermore, the safety stock period may be another predetermined length of time designed to increase the preliminary order quantity as a safety measure. The safety stock period may reduce the risk of running out of stock in cases of unexpected events such as a sudden increase in demand or an unanticipated shipping delay. In some embodiments, TIP 323 may set the safety stock period based on the coverage period, where, for example, a safety stock period of 0 days is added when a coverage period is 1-3 days, 1 day is added when a coverage period is 4-6 days, or 3 days are added when a coverage period is greater than 7 days.

Despite the complex process of determining the preliminary order quantities described above, the preliminary order quantity may be based primarily on customer demand and not take real-world constraints into account. Steps for accounting for such constraints are thus desired in order to optimize product inventories. TIP 323, in some embodiments, may adjust the preliminary order quantities using a set of rules configured to fine tune the preliminary order quantities based on data such as sales statistics, the current product inventory levels, or the currently ordered quantities.

The resulting quantities, recommended order quantities, may be transmitted to PO generator 326. In other embodiments, the resulting quantities may be further processed by IPS 324 to prioritize particular products and/or distribute the quantities to one or more FCs.

In some embodiments, IPS 324 may include one or more computing devices configured to determine a popularity for each product, prioritize the order quantity based on the determined popularity, and distribute the prioritized order quantity to one or more FCs 200. Moreover, the computing devices may further determine a FC for a product and assign the product to the determined FC. Components of IPS 324, which may be configured to determine a FC and distributing products to the determined FC, are described below in more detail with respect to FIG. 4 .

Manual order submission platform 325, in some embodiments, may include one or more computing devices configured to receive user inputs for one or more manual orders. Manual order submission platform 325 may comprise a user interface accessible by a user via one or more computing devices such as internal front end system 105 of FIG. 1A. In one aspect, the manual orders may include extra quantities of certain products that the user may deem necessary and allow manual adjustments (e.g., increasing or decreasing by a certain amount) of the preliminary order quantities, the recommended order quantities, the prioritized order quantities, or the distributed order quantities. In another aspect, the manual orders may include a total quantity of certain products that should be ordered as determined by an internal user instead of the order quantities determined by SCM 320. Still further, a user may specify, in some embodiments, a particular FC as a receiving location so that the manual orders may get assigned to the particular FC. In some embodiments, portions of the order quantities submitted via manual order submission platform 325 may be marked or flagged (e.g., by updating a parameter associated with the portion of the order quantity) so that they may not be adjusted (i.e., constrained) by TIP 323 or IPS 324.

In some embodiments, manual order submission platform 325 may be implemented as a computer or computers running software such as the Apache HTTP Server, Microsoft Internet Information Services (IIS), NGINX, or the like. In other embodiments, manual order submission platform 325 may run a custom web server software designed to receive and process user inputs from one or more user terminals 330 and provide responses to the received user inputs.

PO generator 326, in some embodiments, may include one or more computing devices configured to generate and provide POs to one or more suppliers based on the recommended order quantities or results of the distribution by IPS 324. SCM 320, by this point, would have determined a recommended order quantity for each product that requires additional inventory and for each FC 200, where each product has one or more suppliers that procure or manufacture the particular product and ship it to one or more FCs. A particular supplier may supply one or more products, and a particular product may be supplied by one or more suppliers. When generating POs, PO generator 326 may issue a paper PO to be mailed or faxed to the supplier or an electronic PO to be transmitted to the same.

Report generator 327, in some embodiments, may include one or more computing devices configured to generate reports periodically in response to a predetermined protocol or on-demand in response to user inputs via, for example, user terminals 330 or internal front end system 105 of FIG. 1A. The reports may range from simple reports that output information such as the recommended order quantity for a particular product or complex reports that require analysis of historical data and visualize such information in a graph. More specifically, report generator 327 may generate reports including information such as how order quantities changed from the forecasted quantities to the final quantities at each step of the adjustments performed by SCM 320; a history of how many resources at each FC 200 were utilized; differences between the forecasted quantities and the final quantities (e.g., quantities that had to be reduced from the forecasted quantities in order to account for real-world limitations) by product category; or the like.

User terminals 330, in some embodiments, may include one or more computing devices configured to enable internal users, such as those working at a FC 200, to access SCM 320 via manual order submission platform 325 or report generator 327. User terminals 330 may include any combination of computing devices such as personal computers, mobile phones, smartphones, PDAs, tablets, or the like. User terminals 330 may include a display. The display may include, for example, liquid crystal displays (LCD), light emitting diode screens (LED), organic light emitting diode screens (OLED), a touch screen, and other known display devices. The display may show various information to a user (e.g., data from FC database 312, demand forecasts from demand forecast generator 322, supplier statistics data, current product inventory levels, currently ordered quantities of each product, prompts for users to input manual orders, reports from report generator 327, etc.). User terminals 330 may include one or more input/output (I/O) devices. The I/O devices may include one or more devices that allow user terminals 330 to send and receive information from users or another device. The I/O devices may include various input/output devices, a camera, a microphone, a keyboard, a mouse-type device, a gesture sensor, an action sensor, a physical button, an oratory input, etc. The I/O devices may also include one or more communication modules (not shown) for sending and receiving information from systems 100 or 300 by, for example, establishing wired or wireless connectivity between user terminals 330. In some embodiments, the internal users may use user terminals 330 to access a web interface provided by manual order submission platform 325 in order to submit one or more manual orders.

FIG. 4 is a block diagram of IPS 324 including components that may determine a FC 200 in which to store a product and assign the product to the determined FC 200, consistent with disclosed embodiments. IPS 324 may include mapping system 401, SKU system 402, rules system 403, storage system 404, and monitoring system 405. Mapping system 401, SKU system 402, rules system 403, storage system 404, or monitoring system 405 may operate collaboratively to intelligently distribute products to a FC.

Mapping system 401 may interact with SKU system 402, rules system 403, storage system 404, or monitoring system 405 to determine a FC 200 in which to store a product and assign the product to the determined FC 200. For example, mapping system 401 may receive a request to assign a product to a FC 200, retrieve relevant data from SKU system 402, rules system 403, or storage system 404, determine a FC 200 in which to store the requested product based on the retrieved relevant data, and assign the product to the determined FC 200. Mapping system 401 may provide a map of list of products that FCs can support. Mapping system 401 may further execute a validation on the product-FC assignment. An exemplary process for assigning a product to a determined FC 200 by mapping system 401 and executing a validation on the product-FC assignment is illustrated in FIG. 5 and is discussed in more detail below.

SKU system 402 can be configured to provide a plurality of attributes associated with a requested product to mapping system 401 upon receiving a request. For example, SKU system 402 may receive a request to provide a plurality of attributes associated with a product from mapping system 401, retrieve the requested plurality of attributes from FO system 113, and transmit the retrieved plurality of attributes to mapping system 401. The plurality of attributes may include SKU dimensions (e.g., length, width, height, and weight), a unit quantity, a storage type, a category, a price, a sales band, a velocity, a delivery type, a supplier, etc.

Rules system 403 can be configured to provide a stored plurality of rules to mapping system 401 upon receiving a request. For example, rules system 403 may receive a request to provide a plurality of rules from mapping system 401, retrieve the requested plurality of rules, and transmit the retrieved plurality of rules to mapping system 401. Exemplary rules may include basic rules, supplier-SKU rules, supplier rules, SKU rules, dumbbell rules, and category rules. The basic rules may refer to assigning a product to a FC 200 recommended by a predefined rule. The supplier-SKU rules may refer to assigning a product to a FC 200 by using a fixed FC list recommended by SKU exception rules. SKU exception rules may include processing some SKUs with an exception logic that overrides the placement for the SKUs decided by system 324 (or any system of system 300) based on a received request. For example, system 324 may decide that a SKU may be allocated to a plurality of FCs based on the SKU's demand and attribute. An exception rule for the SKU may be created based on a supplier's decision that the SKU may only be delivered to a desirable subset of the plurality of FCs. Based on the exception rule for the SKU, system 324 may decide to allocate the SKU to an FC of the subset of FCs. The supplier rules may refer to assigning a product to a FC 200 by extracting FCs that are listed by a supplier associated with the product, comparing the extracted FCs with the FCs recommended by a predefined rule to detect any overlapping FCs, and assigning the product to one of the detected FCs. If no overlapping FCs are detected, then the product may be assigned to a FC 200 recommended by the predefined rule.

The dumbbell rules may refer to assigning a product to a FC 200 by using FCs recommended by the dumbbell exception rules. The dumbbell rules may be a subset of SKU exception rules that are created to support FC operational needs. For example, dumbbell SKUs may be assigned to multiple FCs, but the dumbbell exception rules (which may be created based on FC operational needs) may assign the dumbbell SKUs to a particular FC that is equipped to process the associated product group efficiently (e.g., the particular FC's associates may be better trained for the associated product group). The category rules may refer to assigning a product to FC 200 by using FCs recommended by a category rule set. The category rules may cause system 324 (or any system of system 300) to recommend a list of FCs which may process SKUs belonging to the same category most efficiently. For example, category rules for the clothing/fashion category may determine whether a FC includes a clothes hanger rack or not. Rules system 403 may comprise a user interface accessible by a user via one or more computing devices such as internal front end system 105 of FIG. 1A. The user may interact with the user interface to upload, modify, and delete one or more rules among the plurality of rules.

Storage system 404 can be configured to store validation use cases that may be used by mapping system 401 to operate a validation on an assigned product. The validation use cases may include cases in which mapping system 401 determines that an assigned product (e.g., an assignment that links the product to a supplier-SKU identification) is invalid. For example, mapping system 401 may analyze the assigned product and determine that the assigned product is invalid if mapping system 401 determines that the assignment is empty, the vendor is empty or null, the assignment includes an empty FC list, the assignment includes an invalid FC list, or duplicate records of the product exist. The validations operated by mapping system 401 may increase the accuracy of the product assignments to FCs, thereby increasing the efficiency of inbound product distribution.

Monitoring system 405 may inspect real time SKU and supplier SKU changes. For example, monitoring system 405 may receive real time updates for any SKU attributes or rule changes, including supplier exception rules. Based on the received real time updates, system 300 may re-calculate SKU assignment logic and rule updates such that SKU attributes and rules are up to date.

FIG. 5 is an exemplary flow chart of process 500 for intelligent distribution of products, consistent with the disclosed embodiments. While FIG. 5 is described with respect to mapping system 401, one of ordinary skill in the art will recognize that other configurations using systems 100, 300, or components thereof, are possible.

In step 501, mapping system 401, implemented in IPS 324, may receive a request to assign a product to a location (e.g., FC 200) from a user device. For example, a computing device may request to assign a product to a FC 200 to IPS 324 via internal front end system 105 of FIG. 1A. In some embodiments, mapping system 401 may automatically assign products to different locations (e.g., FC 200) in order to optimize product inventory. IPS 324 may comprise a user interface accessible by a user via internal front end system 105. The product can be defined by a stock-keeping unit (SKU) or a vendor identification.

In step 502, mapping system 401 may retrieve a plurality of attributes associated with the product from SKU system 402. As described above with respect to FIG. 4 , SKU system 402 can be configured to store attributes of products, retrieve the requested plurality of attributes from FO system 113, and transmit the retrieved plurality of attributes to mapping system 401. The plurality of attributes may include SKU dimensions (length, width, height, and weight), a unit quantity, a storage type, a category, a price, a sales band, a velocity, a delivery type, a supplier, etc.

In step 503, mapping system 401 may retrieve a plurality of rules from rules system 403. As described above with respect to FIG. 4 , rules system 403 can be configured to store a plurality of rules, retrieve the requested plurality of rules, and transmit the retrieved plurality of rules to mapping system 401. The retrieved plurality of rules can be applied sequentially based on a priority associated with each rule. Exemplary rules may include basic rules, supplier-SKU rules, supplier rules, SKU rules, dumbbell rules, and category rules. In some embodiments, the priority of the rules group may depend on the number of rules in the rules group. For example, the highest priority rules may be the supplier-SKU rules while the lowest priority rules may be the category rules, as shown in Table 2 below. Rules system 403 may comprise a user interface accessible by a user via one or more computing devices such as internal front end system 105 of FIG. 1A. The user may interact with the user interface to upload, modify, and delete one or more rules among the plurality of rules.

TABLE 2 Sample rules group priority ranking Rules Rules Priority Rank Total Number of Rules Supplier-SKU 1 43,862 SKU 2 24,616 Dumbbell 3 4 Supplier 4 85 Basic 5 19 Category 6 5,215

In step 504, mapping system 401 may determine a FC 200 to store the product by applying the retrieved plurality of attributes from step 502 to the retrieved plurality of rules from step 503. For example, mapping system 401 may apply the plurality of attributes to the plurality of rules described in FIG. 4 in order of its priority. By way of further example, mapping system may apply the attributes to the supplier-SKU rules, the SKU rules, the dumbbell rules, the supplier rules, the basic rules, and the category rules, respectively until mapping system finds a FC 200 to store the product. Mapping system 401 may apply the attributes to the rule in any combination.

In step 505, mapping system 401 may assign the product to the determined FC 200. As described above with respect to step 504, mapping system 401 may apply the plurality of attributes to the plurality of rules, respectively in order of rules priorities, until mapping system 401 determines a FC 200 to store the product. For example, mapping system 401 may apply the plurality of attributes to the supplier-SKU rules and determine that there are no FCs in which to store the product based on the supplier-SKU rules. Mapping system 401 may apply the plurality of attributes to SKU rules and determine that there are FCs in which to store the product based on the SKU rules. When mapping system 401 determines the FC 200, mapping system 401 may assign the product to the determined FC 200.

In step 506, mapping system 401 may operate a validation on the assigned product from step 505. Mapping system 401 may retrieve one or more validation use cases from storage system 404. The validation use cases may include cases in which mapping system 401 determines that the assigned product (e.g., an assignment that links the product to a supplier-SKU identification) from step 505 is invalid. For example, mapping system 401 may analyze the assigned product and determine that the assigned product is invalid if mapping system 401 determines that the assignment is empty, the vendor is empty or null, the assignment includes an empty FC list, the assignment includes an invalid FC list, or duplicate records of the product exist.

In step 507, mapping system 401 may reassign the product based on the validation from step 506. In some embodiments, IPS 324 may reassign the prioritized order quantity to one or more FCs. In some embodiments, IPS 324 may initially assign the prioritized order quantity to locations based on the set of rules. In another embodiments, IPS 324 may assign the order quantities to each FC based on the current product inventory level of each product at each FC; a level of demand for a particular product from each FC; or the like.

IPS 324 may assign all prioritized order quantities and determine an estimated delivery date for each product. One or more of the FCs may have a total quantity for a particular date that exceeds the FC's intake processing capacity for the particular date. In this case, IPS 324 may determine an amount of the quantities over the intake processing capacity and transfer corresponding quantities to one or more other FCs that are below their respective intake processing capacities for the particular date. In this case, IPS 324 may split the exceeded amount among the one or more other FCs in any suitable way as long as an intake processing capacity of a receiving FC is not exceeded as a result. For example, IPS 324 may split the exceeded capacity into equal portions among the other FCs; split the exceeded capacity based on ratios of available capacity at each FC so that the FCs will have the same ratio of available capacity (e.g., all FC will have quantities that reach 90% of their respective intake processing capacities); or the like. In some embodiments, IPS 324 may transfer a greater portion of the exceeded capacity to FCs nearest to the FC with an exceeded capacity or adjust the portions in a way that minimizes any additional shipping costs that may arise.

IPS 324 may communicate to PO generator 326 to generate POs based on the assigned order quantities for each FC. In one aspect, there may be more than one PO generator 326, each of which are associated with a particular FC. In this case, the particular PO generator 326 assigned to each FC may generate the POs to the appropriate supplier for the order quantities distributed to its own FC. In another aspect, PO generator 326 may be part of a centralized system that generates all POs for all FCs by changing delivery addresses of the POs based on where a particular quantity of products is distributed. A combination of the two embodiments is also possible, where there may be more than one PO generator 326, each of which are associated with one or more FCs and are in charge of generating POs for all FCs with which it is associated.

In step 508, mapping system 401 may adjust the priority associated with each of the plurality of rules based on the validation. IPS 324 may prioritize the order quantity based on real-world constraints at a national level, such as a capacity of location (e.g., FC 200) to handle the product, a popularity of the product, etc. The real-world constraints may include a capacity of location to handle the product and a popularity of the product, wherein the popularity of the product is determined by demand forecast data (order quantity) associated with the product or outbound shipments of the product. In some embodiment, IPS 324 may calculate the popularity (or “velocity”) of the product on an individual basis, using 80% of the demand forecast data and 20% of the historical outbound shipments of the product (other embodiments and values are possible as well). The real-world constraints may further include physical constraints of FCs. For example, a first FC may be capable of handling a tote (for items to be stored at the first fulfilment center) having dimensions of 450 mm×385 mm×350 mm. If an item is bigger than the tote size, the item may not be fulfilled in the first FC because the tote carries the item to transfer within the first FC by a conveyer. IPS 324 may manage such constraints associated with the physical constraints to ensure that an item is not assigned to a FC which not equipped to handle the item of such size.

The prioritization may be processed using two methods. The first method comprises utilizing a set of rules which defines an assignment of predefined quantity of a product to predetermined locations with capabilities to handle large volumes of the product. For example, a set of rules may define assigning the first 5,000 SKUs of the most popular product in five FCs, wherein the FCs have capabilities to handle large volumes of products. The assigned SKUs may be further assigned to regions associated with the FCs. The second method comprises utilizing a logistical regression model to prioritize the order quantity using real-world constraint inputs. IPS 324 may process different algorithms and configurations on the regression model and select the best result. The algorithms may comprise a “redundant SKU first” algorithm, a “singly mapped SKU first” algorithm, and a “randomization” algorithm. The redundant SKU first algorithm may process items (SKU) by their popularities from fast to slow, such that a first item associated with fast popularity is assumed to sell quicker than a second associated with slow popularity. The singly mapped SKU algorithm may process an item which is only mapped to a single FC. The randomization algorithm may randomize the order in which SKUs are processed.

Process 500 or portions thereof may be performed by IPS 324. In some embodiments, IPS 324 may repeat steps 501-504 at predetermined intervals such as once a day. Still further, IPS 324 may perform process 500 for all, or substantially all, products that have been stocked or sold before.

While the present disclosure has been shown and described with reference to particular embodiments thereof, it will be understood that the present disclosure can be practiced, without modification, in other environments. The foregoing description has been presented for purposes of illustration. It is not exhaustive and is not limited to the precise forms or embodiments disclosed. Modifications and adaptations will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed embodiments. Additionally, although aspects of the disclosed embodiments are described as being stored in memory, one skilled in the art will appreciate that these aspects can also be stored on other types of computer readable media, such as secondary storage devices, for example, hard disks or CD ROM, or other forms of RAM or ROM, USB media, DVD, Blu-ray, or other optical drive media.

Computer programs based on the written description and disclosed methods are within the skill of an experienced developer. Various programs or program modules can be created using any of the techniques known to one skilled in the art or can be designed in connection with existing software. For example, program sections or program modules can be designed in or by means of .Net Framework, .Net Compact Framework (and related languages, such as Visual Basic, C, etc.), Java, C++, Objective-C, HTML, HTML/AJAX combinations, XML, or HTML with included Java applets.

Moreover, while illustrative embodiments have been described herein, the scope of any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those skilled in the art based on the present disclosure. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application. The examples are to be construed as non-exclusive. Furthermore, the steps of the disclosed methods may be modified in any manner, including by reordering steps and/or inserting or deleting steps. It is intended, therefore, that the specification and examples be considered as illustrative only, with a true scope and spirit being indicated by the following claims and their full scope of equivalents. 

What is claimed is:
 1. A computer-implemented system for intelligent distribution of products, the system comprising: a memory storing instructions; and at least one processor configured to execute the instructions for: receiving a request to assign a product to a location; retrieving a plurality of attributes associated with the product from a system configured to store attributes of products; retrieving, via a user device, a plurality of rules from a rules system configured to store rules implemented for assigning a product to a location, the retrieved plurality of rules configured by a user using a user interface of the user device, wherein the plurality of rules comprise at least one of supplier-stock-keeping unit rules, supplier rules, stock-keeping unit rules, dumbbell rules, or category rules; determining the location to store the product by applying the retrieved plurality of attributes to the retrieved plurality of rules; assigning the product to the determined location; upon receiving an updated plurality of attributes or an updated plurality of rules, calculating an updated assignment logic based on the updated plurality of attributes or the updated plurality of rules; assigning the product to an updated location based on the updated assignment logic; operating a validation on the assigned product; reassigning the product to another location based on the validation; and adjusting a priority associated with each of the plurality of rules based on the validation.
 2. The computer-implemented system of claim 1, wherein the plurality of attributes associated with the product comprises product dimensions, a quantity of the product, a storage type, a category, a price indicator, a sales band, a velocity, a delivery type, and a supplier.
 3. The computer-implemented system of claim 1, wherein the product is defined by a stock-keeping unit or a vendor identification.
 4. The computer-implemented system of claim 1, wherein the retrieved plurality of rules is applied sequentially based on the priority associated with each rule.
 5. The computer-implemented system of claim 1, wherein operating the validation on the assigned product further comprises retrieving one or more validation use cases.
 6. The computer-implemented system of claim 5, operating the validation on the assigned product further comprises comparing the retrieved one or more validation uses cases against the assigned product.
 7. The computer-implemented system of claim 6, wherein the instructions further comprise reassigning the product to another location based on the comparison.
 8. The computer-implemented system of claim 7, wherein the retrieved one or more validation use cases are configurable.
 9. The computer-implemented system of claim 7, wherein the priority associated with each of the plurality of rules is adjusted based on the comparison.
 10. The computer-implemented system of claim 7, wherein one or more rules of the plurality of rules are adjusted based on the comparison.
 11. A computer-implemented system for intelligent distribution of products, the system comprising: a memory storing instructions; and at least one processor configured to execute the instructions for: retrieving, via a user device, a plurality of rules from a rules system configured to store rules implemented for assigning a product to a location, the retrieved plurality of rules configured by a user using a user interface of the user device; determining the location to store the product by applying the retrieved plurality of attributes to the retrieved plurality of rules; assigning the product to a location by applying the retrieved plurality of attributes to the retrieved plurality of rules; calculating an updated assignment logic based on updated plurality of attributes or the updated plurality of rules; and assigning the product to an updated location based on the updated assignment logic.
 12. The computer-implemented system of claim 11, wherein the instructions further comprise retrieving a plurality of attributes associated with the product.
 13. The computer-implemented system of claim 11, wherein the product is defined by a stock-keeping unit or a vendor identification.
 14. The computer-implemented system of claim 11, wherein the retrieved plurality of rules is applied based on a priority associated with each rule.
 15. The computer-implemented system of claim 11, wherein the instructions further comprise retrieving one or more validation use cases.
 16. The computer-implemented system of claim 15, wherein the instructions further comprise comparing the retrieved one or more validation uses cases against the assigned product.
 17. The computer-implemented system of claim 16, wherein the instructions further comprise reassigning the product to another location based on the comparison.
 18. The computer-implemented system of claim 17, wherein the retrieved one or more validation use cases are configurable.
 19. The computer-implemented system of claim 17, wherein the priority associated with each of the plurality of rules is adjusted based on the comparison.
 20. The computer-implemented system of claim 17, wherein one or more rules of the plurality of rules are adjusted based on the comparison. 